Nail file

ABSTRACT

A nail file comprises a core of stiff sheet material and a layer of abrasive material laminated to at least one surface of the sheet material.

The present invention relates to the field of manicure and pedicureappliances. In particular, a novel nail file and polisher is described.

There are currently two principle types of nail files or polishers inpopular use. There are solid metal (usually steel) files with integralfiling surfaces, usually formed by stamping or grinding an abrasivesurface onto one or both surfaces of a steel sheet or strip. These filesare quite durable, but they are also relatively expensive, especiallywhen a very fine grade of file is required.

The second kind of file currently available is manufactured fromcardboard or very thin wood, which is provided with an emery finish. Ascan be expected, such a product is fairly inexpensive, but not verydurable.

The objects of the present invention, therefore, are to provide aninexpensive, durable nail file, and a method of manufacturing same.

In one broad aspect, the present invention relates to a nail filecomprising (a) a core of stiff sheet material; and (b) a layer ofabrasive material laminated to at least one surface of said sheetmaterial (a).

In another broad aspect the present invention relates to a method ofmanufacturing a polisher and nail file comprising the steps of (a)providing a stiff sheet or strip of base material; (b) providing atleast one source of abrasive substrate, adjacent said base material (a);(c) providing at least one source of heat activated adhesive filmadjacent said substrate and said base material, whereby said heatactivated adhesive film can be drawn with said substrate into contactwith said base material, between said base and said substrate; (d)drawing said substrate and said film into contact with said base asaforesaid, and applying heat, between 300° F. and 500° F., and pressure,to said base, film and substrate, to laminate said substrate to saidbase and thereby form a laminate (e); and cutting said laminate intonail files.

Preferably, in the method of the present invention said base isaluminum, from 0.4 mm thick to 1.O mm thick, preferably 0.5 mm thick;said film is from 0.0127 mm to 0.1524 mm, preferably 0.0254 mm thick,containing from 83%-93%, preferably 88% ethylene, from 5% to 15%,preferably 10% acrylic acid, and from 0% to 7%, preferably 2% ethylvinyl acetate; and said abrasive substrate is waterproof emery cloth orpaper.

In drawings which illustrate the present invention by way of example:

FIG. 1 is a plan view of a nail file according to the present invention;

FIG. 2 is a longitudinal sectional view through the embodiment of FIG.1, with a portion of the view being enlarged to show detail;

FIG. 3 is a schematic representation of the manufacturing process of thepresent invention; and

FIG. 4 is a perspective view of an alternative embodiment of the nailfile of the present invention.

Referring to FIGS. 1 and 2 together, the nail file of the presentinvention indicated generally as F, includes an aluminum core 1, shapedas a conventional nail file and a strip of waterproof emery paper orcloth 2 adhesively attached to the aluminum core 1 by means of a heatactivated adhesive film 3.

The preferred heat activated adhesive film 3 is a random co-polymer ofethylene and activated adhesive, with a minor vinyl acetate component.Typically, the film will be from 0.0127 mm to 1524 mm, (i.e. from 0.5mil to 6 mil) preferably 0.0254 mm (1 mil) thick, containing from83%-93%, preferably 88% ethylene, from 5% to 15%, preferably 10% acrylicacid, and from 0% to 7%, preferably 2% ethyl vinyl acetate. Such a filmis commercially available as Dow "899", or "709". In a preferredembodiment, aluminum core 1 is about 0.5 mm thick, emery cloth 2 is from200 to 1200 grade, most preferably 400 grade, and film 3 is 1 mil thickDow "899" or "709".

Optionally, aluminum core 1 may be pre-treated, for instance byvapour-deposition, with minerals such as nickel, to alter the somewhatdull appearance of aluminum.

In order to manufacture the file of the present invention, the followingprocedure is carried out (referring to FIG. 3):

(a) a 0.5 mm aluminum base 1 is unrolled off a roll, and into alaminating area;

(b) the aluminum base is then pre-heated, by infrared, flame, or otherknown pre-heat method (pre-heat area indicated as P);

(c) Dow "899" or "709" adhesive film 3 is unwound from a pair of rollsflanking the aluminum base stock, and downstream of the film rolls, apair of rolls of waterproof emery paper or cloth 2 is aligned with thefilm 3 rolls.

(d) by means of secondary rollers 4, the film 3 is brought into contactwith each side of the aluminum base stock 1, and the emery 2 is pressedonto the film. The five layer emery-film-aluminum-film-emery combinationis then pressed between a pair of heated laminator rolls 5, at atemperature of 300° F. to 500° F.;

(e) the combination then passes through a chiller C, such as an airchiller or chilled rolls, and then to a die-cutter D, where nail filesare stamped from the laminate.

It will be understood that other metals besides aluminum may be utilizedin the present invention. Aluminum is preferred because it isinexpensive, resilient, and capable of holding an attractive finish.Moreover, stiff plastic may be utilized instead of aluminum, (in whichcase, pre-heating will not be carried out) and a very good productobtained. Also, it can be seen, in FIG. 4, that the nail files of thepresent invention may be manufactured in shapes other than shown inFIG. 1. Illustrated in FIG. 4 is a shape which lends itself well to useas a manicurists buffer.

It will also be understood that the pre-heating/cooling steps providedin the manufacturing process detailed above are steps of convenience,rather than absolute necessity. By preheating the aluminum substrate,one is permitted to carry out the lamination step more quickly, and at arelatively low temperature. By chilling the product after laminating,one is able to handle immediately the die-cut product without beingburned.

I claim:
 1. A nail file comprising:(a) a long narrow core of aluminum;and (b) a layer of abrasive material laminated under heat and pressureto at least one surface of said core by means of a film of heatsensitive adhesive disposed between said abrasive and said core, saidheat sensitive adhesive being a random co-polymer of ethylene andacrylic acid.
 2. A nail file as defined in claim 1 wherein saidco-polymer also contains vinyl acetate.
 3. A nail file as defined inclaim 2 wherein said co-polymer contains from 83% to 93% ethylene from5% to 15% acrylic acid, and from 0% to 7% vinyl acetate.
 4. A nail fileas defined in claim 3 wherein said co-polymer contains 88% ethylene, 10%acrylic acid and 2% ethyl vinyl acetate.
 5. A nail file as defined inclaim 4 wherein said adhesive film is from 1 to 6 mils thick.
 6. A nailfile as defined in claim 5 wherein said abrasive is laminated to bothsurfaces of said core.
 7. A nail file as defined in claim 5 wherein saidfilm is 1 mil thick.
 8. A nail file as defined in claim 7 wherein saidabrasive is waterproof emery paper or cloth.
 9. A nail file as definedin claim 8, wherein said core is aluminum.
 10. A nail file as defined inclaim 8 wherein said core is aluminum about 0.5 mm thick.
 11. A nailfile as defined in claim 7 wherein said abrasive is waterproof sandpaper.